Mattress construction



June 30, 1964 R. H. BLECKER MATTRESS CONSTRUCTION 2 Sheets-Sheet 1 Filed June 15, 1962 June 30, 1964 H. BLECKER MATTRESS CONSTRUCTION 2 Sheets-Sheet 2 Filed June 13, 1962 f zvfzzzur Z314 VMO/VD H 51-56 i/LN, Maria M United States Patent 3,138,807 MATTRESS CONSTRUCTION Raymond H. Blecker, Homewood, Ill., amignor to Simmons Company, New York, N.Y., a corporation of Delaware Filed June 13, 1962, Ser. No. 202,122 6 Claims. (Cl. 351) This invention relates to mattresses.

The principal object of the present invention is to provide an improved mattress which will retain its shape and overall appearance.

A further object of the invention is to provide a mattress having an erect border and straight linear edges.

Other objects and advantages of the invention will become apparent with reference to the following description and accompanying drawings.

Inthe drawings:

FIGURE 1 is a partially broken-away perspective view of a mattress showing various of the features of the invention;

FIGURES 2 through 4 are enlarged fragmentary elevational views of portions of the mattress of FIG. 1 in various stages of construction;

FIGURE 5 is a partially broken-away perspective view of an alternative mattress construction embodying various of the features of the invention;

FIGURES 6' and 7 are enlarged fragmentary elevational views of portions of the mattress of FIG. 5 in various stages of construction; and

FIGURE 8 is a fragmentary end view of the boxing strip used in the mattress construction shown in FIGS. 1 and 5.

In FIGS. 1 through 4 of the drawings, there is illustrated a mattress 11 which, because of its quilted outer covering, is sometimes referred to as a quilt-top mattress. The mattress 11 incorporates an inner spring assembly 13 which may be of any convenient type but, in the present instance, is of the type shown in the US. patent to Marshall, No. 685,106, i.e., it incorporates a plurality of helical coil springs 15 individually incased in an interconnected series of pockets 17 formed of suitable textile fabric. The series of incased coil springs 15 is preferably arranged in serpentine fashion to closely nest the springs, and is then tied together to complete the spring assembly by suitable ties 19, preferably passed through the middle plane of the mattress as described in the US. patent to Woller, No. 2,805,429, assigned tothe assignee of this invention.

The spring assembly 13 is closely surrounded, in the illustrated construction, by a border or boxing strip 21 formed as a continuous loop. The boxing strip 21 preferably comprises (FIG. 8) an outer layer 23 of sturdy tick ing material, a center layer 25 of padding material such as cotton felt, or the like, and an inner layer 27 of suitable textile sheeting. These layers are preferably secured together by lines of stitching which, in the illustrated embodiment, constitute spaced parallel vertical rows 29. The ticking layer 23 is preferably wider than either the inner layer 27 or the center layer 25 and extends past the edges of each to facilitate the closing of the mattress.

The boxing strip 21 also includes, adjacent each edge, an elongated strip of fabric 31 such as muslin or the like. folded upon itself longitudinally to form a flap 35 of double thickness which is stitched to the boxing strip by tacking stitches 33 at points spaced longitudinally from one another and inwardly of the folded edges of the flap. The flaps 35 facilitate the attachment of the boxing strip 21 to the spring assembly 13 and, as will be explained in further detail shortly, serve to enhance the stability of the entire mattress.

31,138,807 Patented June 30, 1964 In the illustrated embodiment, the boxing strip 21 and the edges thereof, which become incorporated into the edges of the mattress 11, are maintained in straight condition by a border wire 37, disposed along and secured to the edge of the spring assembly 13. The border wire is in turn reinforced by a flysheet 39 and by the flap 35 of the boxing strip 21 to insure that the wire will itself re main straight and maintain a uniform configuration.

Accordingly, after the spring assembly 13 is located Within the boxing strip 21, the insulating or fly sheet 39, comprising a piece of suitable textile sheeting which is both wider and longer than the mattress spring assembly 13, is placed in overlying relation to the top and bottom faces of the spring assembly, with its edge portions extending past the edges of the spring assembly. The fly sheet, as previously mentioned, reinforces the border wire 37 but, in addition, also prevents padding material from working into the spaces between the pocketed coils 15.

The border wire 37 comprises a flat metal band bent in the plane of the band to form a closed rectangular loop having a configuration substantially the same as that of the spring assembly 13. The border wire loop is placed in overlying relation to the fly sheet 39, with each side thereof disposed adjacent a corresponding edge of the spring assembly. The border wire maintains the edges of the mattress straight, and, overlying the peripheral springs of the assembly, also maintains the boxing strip 21 in a relatively straight and upright condition.

The border wire 37 is interconnected with spring assembly 13, the boxing strip 21 and the adjacent fly sheet 35 in a manner which makes these elements mutually reinforcing. This is accomplished in the illustrated embodiment by folding the extending edge portions of the fly sheet 39 over the border wire, preferably to a position in which they completely cover the wire and extend slightly past the inner edge thereof. The adjacent flap 35 of the fabric 31 is then placed over both the border wire and edge portion of the fly sheet. The border wire, the flap 35 and the fly sheet 39 are then fastened as by hog rings 41 to the top convolution of the edge coils of the spring assembly 13. Hog ringing of every other coil has been found to be suflicient.

In the construction thus far described, outward bowing of the border wire loop 37 is resisted by the edge portions of the fly sheet 39 which are folded around the outer edge of the wire, while inward bowing of the loop is prevented by the flaps 35 which are secured to the boxing stri 31,

which in turn bears against the sides of the spring assembly. The border wire loop in turn maintains the edges of the boxing strip as well as the edge rows of coils of the spring assembly in line, and also maintains the boxing strip 21 in an erect position. The combined elements, when thus interconnected, render the entire mattress dimensionally stable and provide it with a trim and pleasing appearance.

Overlying each of the fly sheets 39 is a first layer or batt of padding 43 and, overlying the batt 43, an intermediate sheet 45. Both the batt 43 and intermediate sheet 45 are of a larger size than the spring assembly 13 and are secured by further hog rings 47 to the border wire 37 at points spaced inwardly from their outer edges to provide an overhanging edge portion which is tucked between the flap 35 and boxing strip 21 prior to the closing of the mattress.

When the mattress is provided with a quilted outer covering 49, as illustrated in. FIGS. 1 through 4, the construction thus far described is preferably tufted, as indicated at 51, to further interconnect the fly sheets 39 with the spring assembly 13 and also to interconnect the sheets 45 with each other. The tufting unites the fly sheets 39,

as the padding layers 43 and intermediate sheets 45 with the spring assembly.

After the tufting, the quilting form of the mattress is closed on each face by the outer covering 49 which is preferably prefabricated. As illustrated, the outer covering comprises an outer ticking 53, a batt 55 underlying the ticking, and an inner scrim sheet 57. The three layers are preferably united by an overall pattern of stitching, and the ticking and scrim sheet are preferably overcast along the periphery of the outer cover to prevent loss of the padding 55.

In the closing of the mattress, the overhanging edge portions of the padding layer 43 are tucked intermediate the flap 35 and the inner layer 27 of the boxing strip (FIG. 3). The outer covers 49 are then stitched, as indicated at 59, along their peripheries to the adjacent peripheral edges of the outer ticking layer 23 of the boxing strip 21. Preferably, the stitching 59 secures a tape 61 in overlying relation to the interconnection of the boxing strip 21 and the outer cover 49 to provide a neat and attractive appearance.

As can be seen in FIG. 4, the tucking of the edge portion of the first padding layer 43 into the space between the flap 35 and boxing strip 21 serves to pad out the boxing strip and maintain it in an erect position. It also insures that the upper surface of the border wire will be well padded and hence can not be detected by an occupant of the mattress after the mattress is closed.

An alternative mattress construction embodying various of the features of the invention is shown in FIGS. 5 through 7. This construction is of the type commonly referred to as outer tufted and includes the spring assembly 13, boxing strip 21, fly sheet 39 and border wire 37 which were also part of the quilt-top construction. The border wire, fly sheet, and flap 35 of the boxing strip are hog-ringed to the spring assembly 13 as previously described. The padding layer 43 and intermediate sheet 45 are then also hog-ringed in place.

After the second hog ringing operation, the construction is not tufted immediately but, instead, a second padding layer or batt 63 is placed in overlying relation to the intermediate sheet 45, and a covering or ticking sheet 65 is placed over the second padding layer 63. The second padding layer 63 is preferably of a size similar to that of the first padding layer 43 to again provide an overhanging edge portion which is tucked intermediate the flap 35 and the boxing strip 21.

The mattress is then closed by stitching the periphery of the ticking sheet 65 to the adjacent edge of the boxing strip 21, preferably using a tape 67 (FIG. 7) similar to the tape 61 used with the quilted construction. After closing, the entire construction is tufted as at 69 to unite the various layers and thus further stabilize the border and edges.

The constructions thus described are particularly effective in providing a mattress which will present a trim and well-tailored appearance throughout the life of the mattress. The border wire 37, stabilized by the fly sheet 39, flap 35, spring assembly 13, and tufting 51 or 69, serves to provide a stiff plane of fixed configuration adjacent each face of the spring assembly. The sides of the border wire loop, being relatively fixed in position, serve to maintain the boxing strip 21, as well as the edge of the mattress, in a straight line. In addition, the overlapping edge portions of the padding, when tucked between the flap and boxing strip, serve to maintain the boxing strip erect and well-padded and thereby prevent it from sagging or otherwise losing its shape.

While various structural features of the invention have been shown and described, it should be apparent that various modifications may be made therein without departing from the scope of the invention, as set forth in the following claims.

What is claimed is:

1. A mattress comprising an inner spring assembly ineluding a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fly sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, fabric secured to the inner face of said boxing strip so as to provide a flap adjacent each lateral edge of said boxing strip, a wire loop overlying each of said fly sheets such that a side thereof is disposed adjacent each edge of said spring assembly, means securing together at spaced intervals said fly sheet, said flap, said wire and an end convolution of one of said coil springs, padding material overlying each of said fly sheets, and an outer covering overlying said padding material and secured to the lateral edges of said boxing strip.

2. A mattress comprising an inner spring assembly including a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fly sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, an elongated strip of fabric folded with each of its lateral edge portions doubled upon itself, said fabric being disposed along the inner face of said boxing strip and tacked thereto so as to provide a double-thickness flap adjacent each of the lateral edges of said boxing strip, a wire loop overlying each of said fly sheets such that a side thereof is disposed adjacent each edge of said spring assembly, means securing together said fly sheet, said flap, said wire and an end convolution of one of said coil springs at spaced intervals adjacent the upper and lower edges of said mattress with an edge portion of said fly sheet overlying said wire and said flap overlying said edge portion and wire, padding material overlying each of said fly sheets, and an outer covering overlying said padding material and secured to the lateral edges of said boxing strip.

3. A mattress comprising an inner spring assembly including a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fly sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, an elongated strip of fabric extending along the inner face of said boxing strip and secured thereto at points spaced from its lateral edges so as to provide a flap adjacent each lateral edge of said boxing strip, a loop of wire overlying each of said fly sheets so that a side thereof is disposed adjacent each edge of said spring assembly, means securing together said fly sheet, said flap, said wire loop and an end convolution of one of said coil springs at spaced intervals adjacent the upper and lower edges of said mattress, a layer of padding material overlying each of said border wires and fly sheets with an edge portion thereof extending past the edge portion of said spring assembly on all sides, said extending edge portion being tucked between said flap and said boxing strip, an intermediate sheet overlying each of said layers of padding material, means securing each of said padding layers and said intermediate sheets to the adjacent border wire at spaced intervals, and an outer ticking overlying said padding layer and secured along its edges to a lateral edge of said boxing strip.

4. A mattress comprising an inner spring assembly including a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fiy sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, an elongated strip of fabric extending along the inner face of said boxing strip and secured thereto at points spaced from its lateral edges so as to provide a flap adjacent each lateral edge of said boxing strip, a loop of wire overlying each of said fly sheets so that a side thereof is disposed adjacent each edge of said spring assembly, means securing together said fly sheet, said flap, said wire loop and an end convolution of one of said coil springs at spaced intervals adjacent the upper and lower edges of said mattress, a first layer of padding material overlying each of said border wires and fly sheets with an edge portion thereof extending past the edge portion of said spring assembly on all sides, said extending edge portion being tucked between said flap and said boxing strip, an intermediate sheet overlying each of said inner layers of padding material, means securing each of said inner padding layers and said intermediate sheets to the adjacent border wire at spaced intervals, a second layer of padding material over lying each of said intermediate sheets, and an outer ticking overlying each of said second padding layers and secured along its edges to a lateral edge of said boxing strip.

5. A mattress comprising an inner spring assembly including a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fly sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, an elon gated strip of fabric extending along the inner face of said boxing strip and secured thereto at points spaced from its lateral edges so as to provide a flap adjacent each lateral edge of said boxing strip, a loop of flat wire overlying each of said fly sheets with a side thereof disposed adjacent each edge of said spring assembly, means securing together said fly sheet, said flap, said Wire loop, and an end convolution of one of said coil springs at spaced intervals adjacent the upper and lower edges of said mattress, an inner layer of padding material overlying each of said border Wires and fly sheets with an edge portion thereof extending past the edge of said spring assembly on all sides, said extending edge portion being tucked between said flap and said boxing strip, an intermediate sheet overlying each of said inner layers of padding material, means securing said inner padding layers and said intermediate sheets to the adjacent border wire at spaced intervals, a plurality of tufts connecting said intermediate sheets and extending through said inner padding layers, said fly sheets, and said spring assembly, a second layer of padding material overlying each of said intermediate sheets, and an outer ticking overlying said second layer of padding material, said outer covering being stitched to said second layer of padding material in an overall pattern of stitching and being secured along its edges to a lateral edge of said boxing strip.

6. A mattress comprising an inner spring assembly including a plurality of axially vertical coil springs arranged in longitudinal and transverse rows, a fly sheet covering the top and bottom faces of said spring assembly, a continuous boxing strip surrounding said assembly, an elongated strip of fabric extending along the inner face of said boxing strip and secured thereto at points spaced from its lateral edges so as to provide a flap adjacent each lateral edge of said boxing strip, a loop of flat wire overlying each of said fly sheets with a side thereof disposed adjacent each edge of said spring assembly, means securing together at spaced intervals said fly sheet, said flap, said wire loop, and an end convolution of one of said coil springs at spaced intervals adjacent the upper and lower edges of said mattress, an inner layer of padding material overlying each of said border Wires and fly sheets with an edge portion thereof extending past the edge of said spring assembly on all sides, said extending edge portion being tucked between said flap and said boxing strip, an intermediate sheet overlying each of said inner layers of padding material, means securing said inner padding layers and said intermediate sheets to the adjacent border wire at spaced intervals, a second layer of padding material overlying each of said intermediate sheets with an edge portion thereof extending past the edge of said spring assembly on all sides, said extending edge portion being also tucked between said flap and said boxing strip, an outer ticking overlying each of said second padding layers and being stitched along its periphery to the adjacent periphery of said boxing strip, and a plurality of tufts connecting said outer tickings and extending through said first and second layers of padding material, said fly sheets, said intermediate sheets, and said spring assembly.

References Cited in the file of this patent UNITED STATES PATENTS 2,168,037 Marsack Aug. 1, 1939 2,975,437 Freeman Mar. 21, 1961 3,080,578 Novascone Mar. 12, 1963 

1. A MATTRESS COMPRISING AN INNER SPRING ASSEMBLY INCLUDING A PLURALITY OF AXIALLY VERTICAL COIL SPRINGS ARRANGED IN LONGITUDINAL AND TRANSVERSE ROWS, A FLY SHEET COVERING THE TOP AND BOTTOM FACES OF SAID SPRING ASSEMBLY, A CONTINUOUS BOXING STRIP SURROUNDING SAID ASSEMBLY, FABRIC SECURED TO THE INNER FACE OF SAID BOXING STRIP SO AS TO PROVIDE A FLAP ADJACENT EACH LATERAL EDGE OF SAID BOXING STRIP, A WIRE LOOP OVERLYING EACH OF SAID FLY SHEETS SUCH THAT A SIDE THEREOF IS DISPOSED ADJACENT EACH EDGE OF SAID SPRING ASSEMBLY, MEANS SECURING TOGETHER AT SPACED INTERVALS SAID FLY SHEET, SAID FLAP, SAID WIRE AND AN END CONVOLUTION OF ONE OF SAID COIL SPRINGS, PADDING MATERIAL OVERLYING EACH OF SAID FLY SHEETS, AND AN OUTER COVERING OVERLYING SAID PADDING MATERIAL AND SECURED TO THE LATERAL EDGES OF SAID BOXING STRIP. 